Fabrication of honeycomb-type cellular materials

ABSTRACT

A strip or web of suitable material, such as treated kraft paper, metal foil or the like is drawn between rolls of a slitter, so designed that by means of a very simple adjustment the finished product may have a selected one of a number of sizes and angles of honeycomb-type cells. After slitting, the strip passes through an adhesive applicator having outlets to imprint staggered areas of adhesive on opposite sides of the strip between rows of slits. The applicator is constructed to prevent access of air to the adhesive during its travel from a supply to the imprinting region thus preventing premature setting of the adhesive and clogging of moving parts. Next the slitted web with applied adhesive passes between substantially spaced folding wheels which will accept strips of various thicknesses for pleating and designed to minimize smearing of the adhesive. As the strip passes through the folding wheels the adhesive spacedly joins adjacent pleats. After the pleated material leaves the pleating wheels it is sent to braking apparatus which forms a compaction wherein the adhesive sets. Then the material is drawn from the compaction by pulling apparatus to stretch it, thereby forming the honeycomb-type cells. As the cellular band is pulled its width becomes less. Width-sensing means provides a signal indicating any deviation from a desired width. This signal is applied to control means for the speed of operation of the pulling apparatus to compensate for any incipient deviation from the desired width.

United States Patent [72] Inventor Robert C. Geschwender 1800 CenterPark Road, Lincoln, Nebr. [21] Appl. No. 887,821 1. Fi 24, 6 Division ofSer. No. 652,555, July 11, 1967,

Pat. No. 3,528,334. [45] Patented Sept. 21, 1971 W Y M [54] FABRICATIONOF HONEYCOMB-TYPE CELLULAR MATERIALS 5 Claims, 18 Drawing 51 [52] 0.8.CI 156/596, 270/39, 270/73, 156/197, 156/548, 156/205, 156/474 [51] int.Cl.. 831i 1/22, B65h 45/16 [50] Field of Search 156/197, 204, 205, 459,462, 465, 474, 548, 596; 83/346; 270/39, 40, 73, 79

[ 56] Referencs Cited UNITED STATES PATENTS 379,698 3/1888 Hill 270/733,218,217 11/1965 Geschwender... 156/548 X 3,229,974 1/1966 Banks 270/733. 1 34- 9 1970 e sh i n 13 4 Primary Examiner-Benjamin A. BorcheltAssistant Examiner-James M. Hanley Anorney- Koenig, Senninger, Powersand Leavitt ABSTRACT: A strip or web of suitable material, such astreated kraft paper, metal foil or the like is drawn between rolls of aslitter, so designed that by means of a very simple adjustment thefinished product may have a selected one of a number of sizes and anglesof honeycomb-type cells. After slitting, the strip passes through anadhesive applicator having outlets to imprint staggered areas ofadhesive on opposite sides of the strip between rows of slits. Theapplicator is constructed to prevent access of air to the adhesiveduring its travel from a supply to the imprinting region thus preventingpremature setting of the adhesive and clogging of moving parts. Next theslitted web with applied adhesive passes between substantially spacedfolding wheels which will accept strips of various thicknesses forpleating and designed to minimize smearing of the adhesive. As the strippasses through the folding wheels the adhesive spacedly joins adjacentpleats. After the pleated material leaves the pleating wheels it is sentto braking apparatus which forms a compaction wherein the adhesive sets.Then the material is drawn from the compaction by pulling apparatus tostretch it, thereby forming the honeycomb-type cells. As the cellularband is pulled its width becomes less. Width-sensing means provides asignal indicating any deviation from a desired width. This signal isapplied to control means for the speed of operation of the pullingapparatus to compensate for any incipient deviation from the desiredwidth.

PATENTED save! an 3,607,583 sum 01 or 11 PATENIED SEPZI l97| sum 02 or11 PATENTED SEPZI I97| sum 03 nr 11 PATENTEI] SEPZI I97! 3,607,583

saw on HF 11 QPATENTEI] sum an SHEET 08 [1F 11 PATENIEDsEP21 an sum 07or 11 mama) sEP21 B?! sum as or 11 PATENIEDSEP21 ml 3, 07,583

sum 09 0F 11 FIGJ4.

FABRICATION OF I'IONEYCOMB-TYPE CELLULAR MATERIALS CROSS'REFERENCE TORELATED APPLICATION This application is a division of my copendingapplication, Ser. No. 652,555, filed July II, 1967, now US. Pat. No.3,528,334.

BACKGROUND OF THE INVENTION This application relates-to my improvementsupon structures such as shown in my U.S. Pat. No. 3,218,217, dated Nov.16, I965.

The general field is that of slitting, application of adhesive andpleating of strip material followed by stretching to produce honeycombor like cellular-bands. Several prior art difficulties have occurred asfollows:

1. Substantially only one thickness of strip could be accepted andsuccessfully operated upon by a machine or at least the range wasexceedingly small. The present invention provides for a wider range.

2. The slitter on a given machine would produce only one arrangement ofslits with the result that only one honeycombcell size and directioncould be produced. Generally this direction was perpendicular to theopposite planes of the faces of the cellular product. By means of thepresent'invention, on a given machine and by means of a simpleadjustment, there can be obtained various sizes of honeycomb cells andvarious dispositions of their axes with respect to the faces of theproduct.

3. Other difficulties have been the exposure to air of the adhesive andunequal distances in its travel to points of application. The exposureto air caused setting of the usually quick setting adhesive in and onthe machine parts and required ex cessive down times for cleaning. Theunequal distances caused uneven flow and application of adhesive tovarious areas. The invention avoids these difficulties by protecting theadhesive in the machine parts from access to air and for equal distancesof flow.

4. Trouble has been encountered in stretching compacted pleated materialin that it was difficult to maintain a substantially constant width whenstretched. According to the present invention maintenance of such asubstantially constant width is accomplished.

SUMMARY A cutter roll is provided with axially extending continuousblades which contact the cylindrical surface of a recessed backing roll.The recesses determine where the blades will not cut and are arranged ingroups which are different from one another. Different groups providefor different cell sizes and their angles. By providing for change inthe phasing of the rotations of the cutter and backing rolls changes maybe made in the cell size and angle in the finished product.

The adhesive applicator is provided with a pair of sealed, veined andported manifolds such that all adhesive paths from a supply point tooutlet ports are substantially equal and protected from air. Around eachmanifold is a ported Teflon or like bearing for a rotating applicatorcylinder. The cylinder has ports for timed registration with the bearingports. The outlets of these ports are covered by pervious mats ofmaterial through which the adhesive bleeds from the cylinder outlets.The entire cylinder is wrapped with an impervious fiberglass or likejacket forming a darn which is perforated according to the design of theareas of adhesive desired to be placed on the slitted strip. Any one ofvariously ported jackets may be used. This jacket protects the adhesivewithin the cylinder and in the mats against contact by the air and itsgeometry of porting determines the shapes of the adhesive imprints onthe slitted strip.

Pleating is brought about by interdigitating star wheels having lobeswith wide enough clearances between them for receiving webs of any of alarge range of thicknesses. These do not drive one another but arecarried on shafts which are driven by interdigitating star-shaped drivewheels which have no such clearances. An intermittent drive for thedrive wheels brings about proper angular motions of the folding starwheels.

As regards the system for obtaining a constant width of the cellularproduct, compacted material is stretched out by motorized draw rolls toexpand the cells. This inherently reduces the width of the pleatedmaterial as a function of withdrawal speed. Detecting means operative onthe edges of the drawnout material provide electrical signals responsiveto any incipient deviation from a desired width. Such signals throughconventional circuitry control motor current so that when too narrow awidth is detected the draw rolls are decelerated and when too wide thedraw rolls are accelerated:

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a three-dimensionaldiagrammatic view of apparatus embodying the invention;

FIG. 2 is a view illustrating a pair of cutting and backing rolls of aslitting section of the apparatus;

FIG. 3 is a developed view of the surface of the recessed backing roll;

FIG. 4 is a diagrammatic view of details of a phase angle adjuster foruse between the cutting and backing rolls;

FIG. 5 illustrates various partially stretched cellular forms that maybe produced by changing the phase angle between the cutting and backingrolls;

FIG. 6 is a view illustrating a pair ofidentical adhesive applicatorroll assemblies of an adhesive application section of the apparatus, oneof the roll assemblies being opened to show interior parts;

FIG. 7 is a view illustrating a veined manifold for adhesivedistribution;

FIG. 8 is a development of the veined cylindrical surface of themanifold;

FIG. 9 is a view like FIG. 7 but showing a port-forming sleeve on themanifold, said sleeve forming a bearing for one of an applicator roll;

FIG. 10 is a side view of an adhesive applicator roll to be rotatablycarried on said sleeve;

FIG. 11 is a cross section taken on line l1- 11 of FIG. 10;

FIG. 12 is a right-end view of the rolls of FIGS. 10 and Il;

FIG. 13 is an illustrative layout of various adhesive delivery parts;

FIG. 14 is a general diagrammatic view showing certain foldingapparatus;

FIG. 15 is a horizontal section through parts of the folding apparatus;

FIG. 16 is a detail view of stripping guide means;

FIG. 17 is a fragmentary plan view illustrating the arrangement of slitsand straight adhesive patches as applied to a slitted strip prior tofolding to form (when folded) a product having cells extendingperpendicularly to its faces; and

FIG. 18 is a fragmentary plan view like FIG. 17 but illustrat-DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring to FIG. I, a suitableframework, part of which is shown at numeral 1 supports variousoperating sections of the apparatus, which are as follows: a slittingsection S; an adhesive applicator section A; a folding and pleatingsection P; a turning section T; a braking and compacting section B; anda stretching and finishing section F.

At numeral 3 is shown a strip of suitable material such as kraft paper,metal foil or the like, capable of being slitted and folded for pleatingpurposes. The strip 3 shall have been previously processed for strength,resistance to deterioration, etc., in the uses to which the finalhoneycomb product is to be put.

The strip 3 moves in the direction (see the dart thereon) from asuitable supply at the left and then down into the slitting section S.Rotatably mounted in the slitting section S on shafts 5 and 7 areslitting and backing rolls 9 and I1 respectively. Shaft 5 and thereforethe slitting roll 9 are powered from a gear reduction unit 13 driven bya motor 15. Shaft 7 is driven from shaft 5 through meshed gears 17 and18. This drives roll 11 oppositely and approximately tangently to roll9.

Further details of the slitting and backing rolls 9 and iii are shown inFIGS. 2-4. Appropriately anchored in axial slots and spaced at 45intervals around the surface of the roll 9 are eight cutting blades T9.The cutting edge of each blade is substantially continuous and extendsparallel to the axis of the roll 9. These edges move tangently intokissing engagement with the surface 23 of roll II. In the spaces betweenthe blades 19 are located resilient pads 21, the outer surfaces of whichare located slightly beyond the cutting edges of the blades 19. Thesesqueeze into tangent engagement with roll 11. to draw down the strip 3as it enters section S over roll 11. The backing roll 11 is providedwith recesses of various shapes and distribution. Thus they are in axialranks to be bridged by the blades 19 when the rolls 9 and 11 turnoppositely. Wherever a blade bridges a recess no cutting action occurs.Between recesses in a given rank of recesses tangential action of theblades against the surface of the roll Ill produces ranks of spacedslits transversely to the length of strip S.

FIG. 3 is an enlarged development of the surface of the backing roll 11,the surface being numbered 23. Examples of shapes and distribution ofrecesses are shown thereon. They may for example be placed in threegroups or categories. A first category is indexed L; a second category,M; and a third category, N. The first category L is indicated bycomparatively small circles arranged in eight ranks axially disposedaround cylinder 11 at axial pitch distances designated lY. The recessesL in adjacent ranks in this category L are symmetrically offset thusperipherally forming symmetrically offset files of the recesses L aroundthe cylinder 11. The distances between ranks are designated X. The ranksare bridged by the edges of the blades 19 of roll 9 when in tangentcutting position. Thus the blades will cut crosswise ranks of slits inthe strip S between recesses but no cutting action occurs across therecesses. FIG. 17 illustrates the resulting ranks of slits 25 in strip3. They are symmetrically staggered in adjacent ranks.

Returning to FIG. 3, the recesses in category M are likewise arranged inranks which are also spaced apart a peripheral distance X. Theserecesses instead of being circular have a long axis and are spaced apartalong their rows. a pitch distance Y, which for example is double thatof %Y. Again recesses M in adjacent ranks in category M are staggeredwith respect to those in an adjacent row. However the staggering is notsymmetrical as in the case of recesses L. The recesses M have beenstippled for convenient cognizance of this fact. The peripheral files ofthe recesses in category M form unsymmetrically offset files of recessesaround the cylinder 11 with resulting slits 26 in strip 3 as shown inFIG. 18. These are unsymmetrically staggered in adjacent ranks.

The recesses in category N are also located in ranks which are spacedapart the distance X, the recesses in adjacent rows being symmetricallystaggered. The pitch distances are again Y. The elongated recesses incategory N have not been stippled to distinguish them from the elongatedrecesses in category M which are stippled. The peripheral files of therecesses in category N again form symmetrically offset files of recessesaround the cylinder I I.

It may be mentioned at this time that the small symmetrical recesses incategory L, having the pitch distances of /91, produce in the finalproduct a comparatively fine orthogonal honeycomb product of depth X asshown at the right in FIG. 5.

The longer symmetrically arranged recesses in category N at the greaterpitch Y produce a coarser orthogonal honeycomb product of depth X asshown at the center in FIG. 5.

The longer recesses in category M which are unsymmetrically arrangedalso produce a coarse honeycomb of depth X in the finished product butin this case the axes of the honeycombs produced are angularly disposedbetween the opposite faces of the product as shown at the left in FIG.5.

The gears 17 and I8 determine the phasing of the slitting and backingrolls 9 and ill, so that adjacent pairs of blades will successivelyengage with ranks of recesses of one or another of the categories L, M,N. To make a selection the phase angle between rolls 9 and 11 ischanged. This is easily accomplished by means shown in FIGS. 1, 2 and 4.Thus while gear 17 is keyed to shaft 5, gear 13 is made rotatable on theshaft 7. Beyond the gear 18 the shaft 7 is reduced in diameter as shownat 27 for the axial sliding reception of a hub 29. The reduced portion27 is provided with a key way 31 for the reception of a spline 33 in thehole 35 of the hub to key them together when assembled. Attached to thehub 29 is a plate 37 from which extends a pin 39. When the hub 29 isslipped over the reduced portion 27 and the pin 39 placed in one oranother of properly spaced holes 24 in gear 18, then the gear 18 ineffect becomes keyed in respect to the backing roll 11. A threadedextension 41 from shaft 7 receives a nut 43 which holds the hub 29 andplate 37 in position on the reduced portion 27.

To make a change in the phase angle between the rolls 9 and ii, the nut43 is removed along with the hub 29 and plate 37. This retracts the pin39 from the hole 24 in which it happens to be. Then either roll 9 or IImay be turned independently of the other to rephase them for operationof blades 19 on the ranks of recesses in any desired category L, M or Non roll 11. Then the plate 37 is replaced with pin 39 in theappropriately presented hole 24 and the nut 43 replaced.

As the slitted strip 3 descends from the slitting section S, it passesinto the adhesive-applying section A. The arrangements in this section Aare illustrated in FIGS. 6-13.

There are two identical adhesive applying rolls in section A (FIG. 6)which apply adhesive in spaced patches on opposite sides of the strip 3.Since both rolls are identical, the description of one will suffice forboth. Referring to FIG. 7 numeral 45 indicates a hollow manifoldextending from a hollow inlet block 47 having an inlet fitting 49 forthe reception of adhesive. Since there are two rolls, there will be twoinlet fittings 49 (FIG. 1). The fittings 49 are designed to receivecouplers 51 on the ends of resilient inlet lines 53 for delivery ofadhesive under pressure. The lines 53 are branched from a common trunkline 55 connecting with adhesive supply 57 in a pressure tank 59. Airunder pressure in line 6! drives the adhesive from the tank 59 to thetrunk line 55. it is desired however that the flow of adhesive bemetered. This is accomplished by the use of what is usually referred toas a peristaltic pump, numbered 63. It is driven from a motor 65 througha gear reducer 61'. The pump has revolving rollers 67 which roll uponand squeeze shut the lines 53 which are made of flexible tubing. Thusbetween each pair of rollers a certain amount of adhesive is trappedunder pressure and advanced to the manifolds 45. Thus the pump 63constitutes a metering device for the pressurized adhesive.

Each hollov. manifold 45 has centrally disposed outlets 69 (FIGS. 7 and8) leading out into a central peripheral vein 7! cut into its outersurface. Branch veins 73 lead from vein 71 to vein terminals 75. Theveins 711, 73, 75 may be milled into the outside surface of themanifold. This surface is developed at 77 in FIG. 8. The arrangement issuch that the distance and pressure drop (due to friction) that theadhesive is required to flow through from the interior of the manifold45 to any terminal will be the same. Thus each vein terminal 75 willreceive adhesive at the same rate under pulsation from the meteringdevice 63.

Referring to FIG. 9 there is shown at numeral 79 a closely fittingsleeve which is forced over the manifold 45 with an airtight fit. Thissleeve 79 has outlet ports 81 which register with the vein terminals 75.The inside of sleeve 79 serves to complete the veins 71, 73, as tubularchannels supplying adhesive to the outlet ports 81 on the outside of thesleeve.

The outside of the sleeve 79 forms a bearing for a rotatable adhesiveimprinting cylinder 83 shown more in detail in FIGS. 10-12 and ingeneral in FIG. 6. Its cylindrical interior 85 fits around and isrotatable on the stationary sleeve 79 of the manifold 45. The sleeve iscomposed of an antifr iction material such as Teflon.

Each cylinder 83 has an octagonal exterior shape providing four flats 87from which extend ribs 89 having circular exterior edges. Three of theother four flats 91 have clamping bars 93 held thereon by screws 95. Themarginsof these bars 93 are tongued and grooved as shown at 97 forclamping the margins of elongate strips 99. Thus the strips 99 are heldin arched positions over spaces 101 between-the ribs 89. FIGS. 11 and 13show the strips 99 in place. FIG. 10 shows one strip 99 removed toexpose the ribs 89 and spaces 101 therebetween.

The strips 99 are composed of suitable porous material through which theadhesive used may bleed. Appropriate materials are cellular foamplastic, felt or the like. On the fourth flat 91 the margins of theadjacent strips 99 are held down by tongues 84 of a pair of spaced bars103 held in place by screws 105. These bars 103 are also beveled toreceive between them a V-shaped metal strip 107 drawn into place byscrews 109. Strip 107 holds in place a circumferential jacket or wrapper111. The wrapper 111 is replaceable and is composed of an impervious,material such as plastic impregnated fiberglass. Its margins 112 areheld in place by the V-shaped bar 107.

Adhesive is supplied to the spaces 101 between ribs 89 and under thepervious strips 99. This is accomplished through four sets of passages114 which lead from the inside surface 85 of rotary cylinder, 83. Thesepassages 114 extend radially to the slots 101 between the ribs 89. Asthe cylinder 83 rotates on the sleeve 79 of the manifold 45 the inletsto the passages 114 register successively with the vertical outlet ports81 in said sleeve 79. Thus the strips are intermittently supplied withadhesive as they pass over the vertical position. The vertical outletports 81 are thus oriented to prevent adhesive flow during shutdown.

In order to permit escape of the intermittently supplied adhesive fromthe strips 99 in accordance with a desired pattern, the wrapper 111 isprovided with suitable ranks of ports 113 over the strips 99 as shown inFIGS. 1, 6 and 13, for example. The arrangement is such that as two ofthe cylinders 83 rotate tangently with the strip 3 therebetween and aspassages 114 register with ports 81 there will be successively impressedon one side of the slitted strip 3 ranked areas 115 of adhesive (FIG.17). Likewise there will be imprinted on the other-side of the stripranks of adhesive 117. The ranked patches 115 and 117 on opposite sidesof strip 3 are staggered. All patches start at the junction 124 betweenslits 25 in one rank and extend upwardly to the slit 25 in the nextrank. The extensions of all patches terminate near the center of theslit 25 in the next rank.

To apply patches of adhesive for use with the unsymmetrical slits ofcategory M, the ports in wrapper 111 are angled to apply front and backangled patches of adhesive to the strip 3 as shown at 116 and 118 inFIG. 18. This requires only the substitution of wrappers such as 111 onthe two cylinders 83, containing properly angled ports. Thus theadhesive is protected from access thereto by air until it exudes fromthe mat strips 99 through the ports in the selected wrapper and onto thestrip 3.

In order to drive the pair of cylinders 83 tangently on opposite sidesof the strip 3 each is provided with a coupling means such as shown at86 in FIG. 10. One of these couplings is driven from a power shaft 88and the other from a shaft 90, the shafts 88 and 90 being connectedthrough meshed gears 92.

LII

The strip 3 with the adhesive thus applied descends from the adhesiveapplying Section A to the folding and pleating section P. As shown inFIGS. 14-16, in the pleating or folding section Pa are located shafts119 and 121 mounted on bearings 120, 122. On the shafts are gangs ofstar wheels 123 and 125 respectively held by keys 126. The lobes 128 ofthese wheels interdigitate with ample clearance between the lobes toaccept various thickness of strip 3, as best shown in FIG. 16. Each starwheel is spaced from the next adjacent one by means of a washer 127.Between adjacent wheels are stripping and guide blades 129 (FIG. 16). Asillustrated in FIG. 14, as the strip 3 passes between the gangs of starwheels it is folded into an accordion pleated band 131 which descendsbetween the stripper and guide blades 129. The shafts 119 and 121 alsocarry an additional pair of similar star wheels 133 and 135 respectivelyhaving lobes which intermesh without any substantial clearance at theircusped ends. Wheel 133 drives wheel during part of their revolutions.This driving action has just been completed in FIG. 14. The next lobe130 of wheel 133 is however not in a position to drive the next lobe 130on wheel 135. This is because the lobe forms for folding are notconsistent with such action being designed to bring about best foldingaction by the lobes 128 on the folding wheels 123 and 125. In order toobtain a drive during the next period of movement the shaft 119 isprovided with a disk 137 on which are pin-mounted rollers 139. Thesedrive the spokes 141 of a spider 140 having notches 143 into which therollers travel. The spider is keyed on shaft 121. At the stage shown inFIG. 14 a roller 139 is about to come into driving action with one ofthe spokes 141 of the spider. Now the drive between shafts 119 and 121rather than occurring as it did through the lobes of wheels 133 and 135occurs between a pin 139 on disk 137 and a spoke 141 of the spider. Theshapes of the lobes on star wheels 133 and 135, and the shapes of thenotches 143 are such that optimum conditions of advance of the strip 3through the star wheels 123 and 125 is obtained without requiring thestar wheels 123, 125 which fold the strip 3 to effect any drivingthrough it. Stated otherwise a constant clearance is maintained betweenthe intermeshing lobes of the star wheels 123 and 125. The alternatingdrive from shaft 119 to shaft 121, first through star wheel 133 to 135and then through the disk to spider 140 allows the shapes of the teethon wheels 133, 135 to be shaped without regard to ordinary gear toothdriving requirements but to provide for optimum nontouching foldingactions between wheels 123 and 125.

Below wheels 123, 125, the folded strip takes a pleated form as a band131, the adhesive between folds forming attachments between them. Theband descends between the blades 129 to drive out and guide rollers 145and 147 on shafts 149 and 151 respectively. These are rotatably timed bya set of gears 153. A plate 155 guides the descending band 131 aroundroller 145. Thus the path of the band 131 then becomes horizontal.

To the right of roller 145 (FIG. 1) is a pivoted bar 157 of substantialweight which acts as a friction brake decelerating the band 131 in itsmovement to the right. The result is an area of compaction indicated bynumeral 158 wherein setting of the adhesive is completed. The compactiongradually pushes past the brake.

Coordinately timed drive means for the apparatus is as follows:

Shaft 5 is driven from the speed reduction and motor unit 13, 15. Shaft88 is driven from shaft 5 by a chain or like drive 159. Shaft 90 isdriven from shaft 88 by the gears 92. Shaft 119 is driven by a chain orlike drive 161 from shaft 88. Shaft 121 is driven from shaft 119 partlyby star wheels 133, 135 and partly by plate 137 and spider 140. Shaft149 is driven from shaft 119 by a chain or like drive 163. Shaft 151 isdriven from shaft 149 by gears 153. Thus all of the rotations of theoperating elements in the sections S, A, P and T are cyclically timed.

It will be understood that if desired the compacted band 131 may bedelivered from the brake section B as an intermediate product to bestretched elsewhere into honeycomb form. On the other hand it may bestretched as it comes from section B. In this case the stretchingarrangement forms the stretching and finishing section F (FIG. 1). Thisincludes a pair of friction draw rolls 165, 167 carried on shafts 166,168 which are geared by means of a set of gears 169. The roll 167 isdriven from a motor 171 through a gear reduction drive 173. The actionof the rolls 165 and 167 in accelerating and drawing the band 131 to theright stretches it to open up the honeycomb cells. At the same time thestretched band 160 becomes constricted at its sides and narrower. Thefaster that the rolls 165, 167 turn the narrower the stretched band 160becomes. it is desirable that its narrowed width shall remainsubstantially constant. To accomplish this there is provided a fixedshoe 175 on one side of the band 131 and a movable width-detecting shoe177 on its opposite side. The shoe 177 carries a stern 179 extendinginto an electrical sensing unit 181 which includes a resilient elementbiasing shoe 177 into engagement with the band 131. The unit 181 isconventional and includes electrical circuitry for converting movementsof shaft 179 into signals operative in the motor circuit to slow down oraccelerate the motor. 11" the speed of the rollers 165, 167 is too rapidwith excessive stretching and narrowing of the band, the shoe 177 willrespond by movement toward fixed shoe 175. The resulting signal in theunit 181 causes the motor 171 to slow down, thus terminating anyincipient narrowing of the band. Conversely, if the speed of the rolls165, 167 is too slow then its width will incipiently increase. Thiscauses the shoe 177 to move outwardly forcing stem 179 to produce asignal in the circuitry of 181 to increase the speed of the motor 171.Thus any incipient increase in the width of the issuing band isterminated.

General operation of the apparatus is as follows, referring to FIG. 1:

The roll phasing between rolls 9 and 11 is set. The strip 3 is drawndown between the slitting and backing rolls 1.1. The roll setting issuch that the blades 19 strike against the backing roll 11 across ranksof whatever group of recesses L, M or N is desired to effect slitting.If they strike across the ranks of the small, closely spaced recesses inthe symmetrically disposed category L, then the fine orthogonalhoneycomb structure such as shown at the right in FIG. 5 will beproduced. If they strike across the more widely spaced and widerrecesses in the ranks in symmetrically disposed category N, then coarserorthogonal honeycomb structures such as shown in the middle of FIG. 5will be produced. If they strike across ranks of the widely spaced widerunsymmetrically recesses in category M, then a sloping honeycombstructure will be produced such as shown at the left in FIG. 5. Theadjustment in the phase angle of operation of the rolls 9 and 11 iseasily performed by resetting the position of the pin 39 in one oranother of the holes 24 in the disk 18.

After slitting, the strip 3 descends into the adhesive section A. Thesets of passages 114 of the cylinders 83 register one after another withthe outlet ports 81 in the sleeve 79 on the manifold 45, thusintermittently supplying adhesive through the porous strips 99 and theports 113. Depending upon which type of wrapper 111 is on the cylinderswith straight or sloping ports, adhesive patches are applied as in FIG.17 or FIG. 18.

Then the slitted strip 3 with adhesive applied either as in FIG. 17 orFiG. 18 moves down through the pleating section P to be folded into theband 131. The band descends between blades 129 and then moveshorizontally to form the compaction 158 in the braking section B whereit is decelerated. From the braking section it is drawn out at increasedspeed which stretches and narrows it. The width is kept substantiallyconstant as it leaves the finishing section F. Upon leaving thefinishing section it is provided in the usual manner with suitablyadhered means such as skins of paper, cardboard or the like (not shown)on the upper and lower faces to maintain the open cellular form. Or ifthe material of the constituent web 3 has been selected to beconventionally set by baking, such a baking step may succeed thestretching step instead of application of skins.

In view of the above, it will be seen that the several objects of theinvention are achieved and other advantageous results attained.

As various changes could be made in theabove constructionswithoutdeparting from the scope of the invention, it is intended thatall matter contained in the above description or shown in theaccompanying drawings shall be interpreted as illustrative and not in alimiting sense.

What is claimed is: 1. Means for pleating any of various thicknesses ofwebs, comprising driving and driven shafts, gangs of interdigitatedpleating star wheels on the said shafts for reception of the webtherebetween each of said pleating star wheels having severalnonengageable lobes interdigitating with lobes on the pleating wheels onthe other, each lobe being of a form outlined by convexly curvedsurfaces terminating in substantially a cusp, the operating clearancebetween the lobes being large enough to receive without pinch themaximum thickness of web to be accommodated, means for maintaining saidclearance comprising additional meshed driving and driven wheels on thedriving and driven shafts respectively and positioned outside of thepath of the web as it passes between the pleating star wheels, each ofsaid additional driving and driven wheels also having several lobes, thelobes on the additional driving wheel on the drive shaft being withoutsubstantial clearance in intermittent driving mesh with the lobes of theadditional driven wheel, intermittent drive means between the drivingand driven shafts for intermittently driving the driven wheel to followwithout driving the lobe on the driving wheel. 2. Means for pleating anyof various thicknesses of webs, comprising driving and driven shafts,interdigitated pleating star wheels on said shafts for reception of theweb therebetween, each of said pleating star wheels having severalnonengageable lobes interdigitating with the lobes on the other, theoperating clearance between the lobes being large enough to receivewithout pinch the maximum thickness of web to be accommodated, means formaintaining said clearance comprising additional meshed driving anddriven star wheels on the driving and driven shafts respectively andpositioned outside of the path of the web as it passes between thepleating star wheels, each of said additional driving and driven starwheels also having several lobes similar to those of said pleating starwheels and interdigitating with one another,

the lobes on the additional driving star wheel on the drive shaft beingin intermittent driving contact with the lobes on the additional drivenstar wheel, intermittent drive means between the driving and drivenshafts for intermittently driving the driven star wheel upon loss oflobe con tact until intermittent driving contact is reestablishedbetween a succeeding lobe of the driving star wheel and a lobe of thedriven star wheel.

3. Means for pleating any of various thicknesses of webs which carryadhesive, comprising driving and driven shafts, gangs of interdigitedpleating star wheels on said shafts for reception of the webtherebetween, each of said pleating star wheels having severalnonengageable lobes interdigitating with the lobes on the other, eachlobe being of a form outlined by convexly curved surfaces terminating insubstantially a cusp, the operating clearance between the lobes beinglarge enough to receive without pinch the maximum thickness of web to beaccommodated,

means for maintaining said clearance comprising additional mesheddriving and driven star wheels on the driving and driven shaftsrespectively and positioned outside of the path of the web as it passesbetween the pleating star wheels, each of said additional driving anddriven star wheels also having several lobes similar to those of saidpleating star wheels and interdigitating with one another,

pleating star wheels and including spaced stripping and guide bladeshaving inner ends located between pairs of the members of each gang,said blades extending in pairs outwardly from the pleating star wheelsto guide a pleated band of material moving therefrom.

5. Pleating means according to claim 4, including a pair of drivenrollers at the outer ends of said blades for guiding said band ofpleated material toward a brake to compress the band.

2. Means for pleating any of various thicknesses of webs, comprisingdriving and driven shafts, interdigitated pleating star wheels on saidshafts for reception of the web therebetween, each of said pleating starwheels having several nonengageable lobes interdigitating with the lobeson the other, the operating clearance between the lobes being largeenough to receive without pinch the maximum thickness of web to beaccommodated, means for maintaining said clearance comprising additionalmeshed driving and driven star wheels on the driving and driven shaftsrespectively and positioned outside of the path of the web as it passesbetween the pleating star wheels, each of said additional driving anddriven star wheels also having several lobes similar to those of saidpleating star wheels and interdigitating with one another, the lobes onthe additional driving star wheel on the drive shaft being inintermittent driving contact with the lobes on the additional drivenstar wheel, intermittent drive means between the driving and drivenshafts for intermittently driving the driven star wheel upon loss oflobe contact until intermittent driving contact is reestablished betweena succeeding lobe of the driving star wheel and a lobe of the drivenstar wheel.
 3. Means for pleating any of various thicknesses of webswhich carry adhesive, comprising driving and driven shafts, gangs ofinterdigitated pleating star wheels on said shafts for reception of theweb therebetween, each of said pleating star wheels having severalnonengageable lobes interdigitating with the lobes on the other, eachlobe being of a form outlined by convexly curved surfaces terminating insubstantially a cusp, the operating clearance between the lobes beinglarge enough to receive without pinch the maximum thickness of web to beaccommodated, means for maintaining said clearance comprising additionalmeshed driving and driven star wheels on the driving and driven shaftsrespectively and positioned outside of the path of the web as it passesbetween the pleating star wheels, each of said additional driving anddriven star wheels also having several lobes similar to those of saidpleating star wheels and interdigitating with one another, the lobes onthe additional driving star wheel on the drive shaft being withoutsubstantial clearance in intermittent driving contact mesh with thelobes on the additional driven star wheel, intermittent drive meansbetween the driving and driven shafts for intermittently driving thedriven star wheel upon loss of lobe contact until intermittent drivingcontact is reestablished between a lobe in the driving star wheel and alobe on the driven star wheel.
 4. Pleating means according to claim 3,wherein spacing means are located between the members of each gang ofpleating star wheels and including spaced stripping and guide bladeshaving inner ends located between pairs of the members of each gang,said blades exTending in pairs outwardly from the pleating star wheelsto guide a pleated band of material moving therefrom.
 5. Pleating meansaccording to claim 4, including a pair of driven rollers at the outerends of said blades for guiding said band of pleated material toward abrake to compress the band.